JOURNAL OF TEXTILES AND POLYMERS, VOL. 6, NO. 2, JUNE 2018 77

Cost Comparison of Ring Spun Yarn of China Hui Hong Polyester Fiber and Blended Yarn of Khalis and PSL Polyesters Fiber

Abdul Rauf Shaikh, Rashid Ali Laghari, and Iftikhar Ali Sahito*

Abstract- The theme of this research paper is to create a cost comparison report between yarn made from the expensive China Hui Hong polyester fiber and yarn made by blending ring spun of polyester of less costly Khalis Fiber Limited (KFL) and Pakistan Synthetic Limited (PSL). Polyesters yarns of 30Ne were made on ring spinning frame at different recipes of KFL and PSL, i.e., 100% KFL, 75% KFL+25% PSL, 60% KFL+40% PSL, 50% KFL+50% PSL, 40% KFL+60% PSL, and 100% PSL and then the costs for all fibers compared with those for 100% China optical Hui Hong fiber. Yarn cost and production effecting parameters were determined such as yarn ounces per spindle (OPS), yarn yield and monthly profit. Based on the results, comparison reports were made using Uster Tester 4. The theme of this report is to establish a methodology to achieve more margin with demanding market trends, customer requirement, and product application for yarn spinning industry.

Keywords: OPS, Yield%, spindle cost, conversion cost

I. INTRODUCTION

Ring spinning is the oldest and most versatile process for making different types of yarns from textile fibers

[1]. No one can deny its importance till the early 1960s. Then it was felt that this process has high capital investment together with a high raw material cost [2]. Therefore, different experiments have been performed to make yarns with low raw material cost and [3] high profitability range.Blending of fibers which differ in properties, with a view to achieving or improving certain characteristics of the yarn has been worked since many years ago [4]. The blend is an intimate mixture of staple fibers of different structures, lengths, diameters or colors. Fabrics made from blending

A.R. Shaikh and I.A. SahitohDepartment of Industrial Engineering, Mehran University of Engineering & Technology, Jamshoro 76062, Pakistan.

R.A. LaghariSchool of Mechatronics Engineering, HerbinInstitute of Technology, Herbin 50001, Republic of China.

Correspondence should be addressed to I.A. Sahitoe-mail: iftikhar.sahito@faculty.muet.edu.pk

of yarn types have better properties than those made from a single yarn [5,6].

The blending of cotton fiber with polyester fiber is done to enhance drape properties, comfort ability, dye ability and many other properties of the fabric products [7,8]. In the cotton/polyester blends, polyester fiber plays an outstanding role in all areas of the life-saving medical textiles to the geo-textiles [9,10]. The advantages of polyester over other fibers are strength, luster and aesthetics properties [11,12]. The polyester fibers do not possess a high absorption of water and wick less water. In this research project, there is focus on the economic growth, quality of product and profitability range. It will focus on to set manufacturing process parameters so that yarn spinning industry earns more profit, changing market trends, customer requirement, product application and product properties on demand to maintain standard quality and productivity of yarn as per customer requirement. Due to high crisis, there are requirements to form recipes of different types of fibers in such ratios as final quality and profitable product can be made. This research was conducted to investigate the final qualitative and profitable product of the yarn via blending of PSL and Khalis polyesters, achieving the quality parameters and maximizing profitable range. Recipe of the KFL and PSL polyesters fibers in different ratios were made to achieve the required strength and quality characteristics of qualitative yarn. Due to improper control of recipe in blow room process by operator, we suggest the new model for the spinning process to run in an efficient way and mix fibers, which is required for a recipe that set for quality development and profitable product. By controlling manufacturing process with semi-automated devices this provides easiness to the operator to control manufacturing process in an efficient way, which produces the final quality product.

Due to weather changes in different seasons, temperature varies from 4 °C to 50 °C. Change in temperature causes trouble in controlling precise moisture in fiber mat to develop the quality product. For avoiding these issues new automated devices have been implemented at the assembly line for the minimization of waste, which automatically

78 JOURNAL OF TEXTILES AND POLYMERS, VOL. 6, NO. 2, JUNE 2018

measures the moisture control, dust cleaning and reduces material wastage as well as controlling the environmental pollution. Moisture and weight of fiber mat can be measured on the assembly line and can be viewed on an LCD screen by operators to monitor and control the process. Data of the manufacturing process can also be stored on the hard drive for future usage and the management purpose. By installing these devices, the operator load and wastage of material arereduced, and manufacturing process becomes precise, accurate and easy to handle.

II. EXPERIMENTALA. Materials and MethodsPolyesters yarns of 30Ne and 1.05 HR were produced on a ring spinning Machine (EJM 178) in different recipes by using PSL, KFL and China Hui Hong polyesters. Sliver in a card department of 65 grains was prepared by using a scutcherin blow-room line and card machine (Mekin). These slivers were then fed by two passages through drawing machines, ie., a breaker drawing machine named Howa Breaker and a finisher drawing machine (RSB D 35) to get uniformity of sliver in drawing department. Following methods are adopted for making different recipes of KFL, PSL and China optical polyesters mixed fibers. The properties of fibers and the temperatures set at different departments of the yarn manufacturing process are listed in Tables I and II, respectively.

B. Methods of Different Fibers1) For 100% polyester/100% China optical:Issuance of bales = ring bags production target, excess 5% of ring target bags × 45.36/bale weight.

Suppose ring production target is 440 bags, excess 5% of =440 × 0.05 = 462 bags.Therefore, mixing for 462 bags = 462 bags × 45.36 (kg) /350 kg= 59.87 bales of 100% polyester.Mixing of fibers in different recipes can be calculated as:2) 25% Polyester + 75% KFL MixingSuppose ring production = 185 bags, 5% extra = 194 bags, = 194 × 45.36 =8811.78 kg (total mixing in kg)For 25% PSL 8811.78 × 25/75 = 29371 kg (25% PSL mixing in kg), 2937/bale weight of PSL 2937/350= 8.39 bales of PSLNow For 75% KFL Total mixing – PSL (25% mixing in kg), 8811.78 – 2937= 5874 kg of KFL5874/bale weight of KFL,5874/255= 23 bales of KFL3) 50% PSL + 50% KFL MixingSuppose ring production = 62 bags, 5% extra = 65 bags

Parameters KFL polyester PSL polyester China polyester

Denier 1.2 1.2 1.2

Length (mm) 51 51 51

Type Dull Semi dull Semi dull

Color R 55 92 80

Color b 45 8 20

No of Crimps 4 13 8

Moisture (%) 0.41 0.39 0.4

Elongation (%) 15 24 19

Tenacity 5 7 6

Shrinkage (%) 3 3.5 3.3

Grade C A B

TABLE IHVI FIBER TESTING OF PSL POLYESTER, KFL POLYESTER AND CHINA POLYESTER

Department Dry bulb (°F) Wet bulb (°F) Humidity (%)

Blow room 75 62 46.5

Card 84 72 56

Drawing 76 63 47

Simplex 77 64 48

Ring spinning 101 83 45

Auto cone 82 70 55

TABLE IITEMPERATURE AND HUMIDITY AT YARN

MANUFACTURING SECTIONS

SHAIKHI ET AL.: COST COMPARISON OF RING SPUN YARN OF CHINA HUI HONG ... 79

PSL bale weight = 350 kgKFL bale weight = 255 kgFirst we balance the bales weight of both therefore 350-255 = 95 kg of PSL should be drawn out from ever PSL bale now both bales are of equal weights then= 65 bags × 45.36/255 = 11.56 bales= total 11.56 bales are requiredNow 50%-50% ratio of both so 11.56 × 0.5 = 5.78 bales of PSL of 255 kg weight =11.56 × 0.5 = 5.78 bales of KFL of 255 kg weightHowever, if we take the PSL bale of 350 kg and 255 kg of KFL bale weightThen we calculate in this way=65×45.36/255 kg = 11.56 bales of both now 50%-50% ratio so 5.78 bales of each but polyester bale weight is not equal to KFL bale weight, so= 5.78 – extra bale weight (95 kg) × total bales for mixing /PSL bale weight= 5.78 ×95×5.78/350= 5.78-1.56 = 4.21bales of PSL of 350 kgThe same method should be followed for the other ratios.

C. Equations and formulaeSc=Expenses(PKR)/number of spindles (1)Spindle cost=amount expensed except raw material charges/spindles installed in millFor example: spindles in mill are 29484Expense =PKR 515970Sc=17.5 (It will be variable monthly)

The factors which contribute to the spindle cost include: salary, wages, bank charges, store consumption, electric bill, gas bill, miscellaneou sexpenses.Cc=16×Sp/OPS (2)Conversion cost = 16×spindle cost/OPS (3)Monthly raw material can be find out by = raw material in kgs× Rate/kg (4)Rate/kg=bale weight price (PKR)/bale weight kg (5)Cost of raw material in pounds=(Rate/kg)/2.2046/yield%

(6)Income=bag weight price in PKR×number of bags in month (7)Income source=waste price/kg×waste in kg on month (8)

Cost analysis of different textile fibers

Fiber Used 100% China

optical100% KFL 100% PSL 75% KFL+25% PSL

60% KFL+ 40% PSL

50% KFL+ 50% PSL

40% KFL+ 60% PSL

Raw Mt (rate/kg)

110 70 150 90 102 110 118

Raw materialcost/Lb

50.91 33.08 68.73 42.09 47.45 50.91 54.34

Yeild of fibers (%)

yield/recovery(%)

98 96 99 97 97.50 98.0 98.50

wast (%) 2.00 4 1.00 3 2.50 2.00 1.50

Yarn breakage(%)

2.50 3.5 1.50 2.8 2.6 2.40 2.00

Count 30/carded 30/carded 30/carded 30/carded 30/carded 30/carded 30/carded

Ops 8.7 7 9.5 7.5 8 8.9 9.1

No of m/cs 57 57 57 57 57 57 57

No of spindles 29484 29484 29484 29484 29484 29484 29484

Spindle cost 17.5 17.5 17.5 17.5 17.5 17.5 17.5

Conversioncost 32.2 40.0 29.5 37.3 35.0 31.5 30.8

Total cost 83.1 73.1 98.2 79.4 82.5 82.4 85.1

Yarn rate/Lb 170 150 200 160 168 175 180

Profit/Loss/lbs 86.9 76.9 101.8 80.6 85.5 92.6 94.9

Total profit/Loss/Monthly

125388877.9 89305309.4 160388463.9 100230324.1 113501334.0 136717337.7 143210250.8

TABLE IIICOST DETERMINATION OF KFL, PSL AND CHINA HUI HONG FIBER

80 JOURNAL OF TEXTILES AND POLYMERS, VOL. 6, NO. 2, JUNE 2018

Profit/loss (monthly) = Amount of all income (amount from sale bags+amount gain from waste)-all expenses (9)China polyester bale net weight is 275 kg (Price = PKR 30250/bale) at millPSL polyester bale net weight=350 kg (Price = PKR 52500/bale)KFL polyester bale net weight=260 kg (Price = PKR 18200/bale)

II. RESULTS AND DISCUSSIONA. Yield Analysis of Khalis Fiber, Pakistan Synthetic Fiber and China Hui Hong FiberFig. 1 shows the yield recovery of PSL, Khalis fiber and China Hui Hong fiber. As seen, the yield recovery increases gradually by increasing the ratio of PSL fiber. The maximum yield recovery values have been obtained at 100% PSL.The higher yield recovery value leads to the lower waste of fiber. From a production point of view it can be said that low yield recovery causes low profit margin.

B. Analysis of Ounces per Spindle of Yarn of Khalis Fiber, Pakistan Synthetic Fiber and China Hui Hong FiberFig. 2 shows the effect of PSL fiber on ounces per spindle

(OPS) of Khalis fiber. As the ratio of PSL fiber increases, the OPS increases gradually. The maximum OPS values have been obtained at 100% PSL.

Higher OPS value means higher production. From a production point of view it can be said that low OPS leads to a low production.

C. Monthly Cost Analysis for Khalis Fiber, Pakistan Synthetic Fiber and China Hui Hong FiberFig. 3 shows the effect of PSL fiber on the monthly profit. As the ratio of PSL fiber increases, the profit margin decreases gradually.

The monthly profit calculated for 50% PSL+50% KFL is about 8600000, which is higher than that for 100% China optical. In addition, the monthly profits calculated for 100% PSL and 60% PSL+40% KFL are both high, but keep in mind that the raw material costs of 100% PSL and

Fig. 1. Yield/recovery% of KFL fiber, PSL fiber and China Hui Hong fiber.

Fig. 2. OPS of Khalis fiber, PSL and China Hui Hong fiber.

Fiber Used 100% China

optical100% KFL 100% PSL

75% KFL+ 25% PSL

60% KFL+ 40% PSL

50% KFL+ 50% PSL

40% KFL+ 60% PSL

Specification 1.2Denx51mm 1.2Denx51mm 1.2Denx51mm 1.2Denx51mm 1.2Denx51mm 1.2Denx51mm 1.2Denx51mm

Fiber type Polyester Polyester Polyester Polyester Polyester Polyester Polyester

Count 30’s 30’s 30’s 30’s 30’s 30’s 30’s

CLSP 4738.23 3838.9 5053.05 4292 4564.75 4724.8 4882.35

Imperfectionindex

73 150 38 128 69 55 50

Uniformity ofyarn (%)

9.80 11 9.60 10 9.90 9.80 9.70

CVm 12.9 15 11.1 13 12.9 12 11.7

TABLE IVCHARACTERISTICS OF ALL TYPES OF PRODUCED YARN

Fig. 3. Monthly profit (in PKR) estimated for KFL,PSL and China Hui Hong Fiber.

SHAIKHI ET AL.: COST COMPARISON OF RING SPUN YARN OF CHINA HUI HONG ... 81

60% PSL+40% KFL are also high. Everyone cannot afford to initialize product.

At the same raw material cost, the profit margin estimated for 50% PSL+50% KFL is higher than that estimated for 100% China optical due to its higher production capacity and higher rate of bag market. By considering customer requirements it is obvious that the quality of 50% PSL+50% KFL is better than that of 100% China optical.

III. CONCLUSIONIn this research project, there was attempted to study economic growth, quality of product and profitability range for different types of fibers. It was totally focused on setting such parameters so that yarn spinning industry earns a lot of profit, changing market trends, customer requirement, product application and product properties on demand to maintain standard quality and productivity of yarn as per customer requirement.

Due to low profitability, there were requirements to form recipes of different types of fibers in such ratios as final quality and profitable product can be made. This research was conducted to investigate the final qualitative and profitable product of the yarn via blending of PSL and Khalis polyesters, achieving the quality parameters and maximizing profitable range. Recipe of the KFL and PSL polyesters fibers in different ratios were made to achieve the required strength and quality characteristics of China optical qualitative yarn.

From the preformed experiments in different ratios of PSL and KFL fibers, it was concluded that whenever the ratio amount of PSL polyester in KFL polyester fiber was increased, more strength, higher productivity and better quality were obtained.

When the experiments were performed using 75% KFL+25% PSL, 60% KFL+40% PSL, 50% KFL+50% PSL, and 40% KFL+60% PSL, the strength and quality increased by increasing ratio % of PSL, as well as the raw material costs increased.

For 50% PSL+50% KFL, the raw material cost was equal to that for 100% China optical but its profit range and quality were good as compared to those of 100% China optical. For the industries using China optical fiber, the 50% PSL+50% KFL blend fiber is a better choice than 100% China optical polyester fiber, 100% PSL is more profitable but to initiate product, it requires high raw material cost, which everyone can not afford. The present research suggests new methods for development of quality products from different cheap recopies. This will be beneficial for industries to save the cost of purchasing high quality of yarn at high market rates.

ACKNOWLEDGEMENTThe authors would like speciallyto thank GM of Amin/Surraya textile MillsPvt Limited, S.I.T.E area Kotri, Pakistan for their support and help in this research study.

CONFLICT OF INTERESTThe authors have no conflict of interest.

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